Holdings: Fundamentals of corrosion

Fundamentals of corrosion: mechanisms, causes, and preventative methods

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Bibliographic Details
Main Author:	Schweitzer, Philip A. (Author)
Format:	Book
Language:	English
Published:	Boca Raton, Fla. [u.a.] CRC Press, Taylor & Francis 2010
Subjects:	Building materials > Corrosion Corrosion and anti-corrosives Korrosion
Online Access:	Inhaltsverzeichnis
Physical Description:	XXIII, 403 S. graph. Darst.
ISBN:	9781420067705

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245	1	0	\|a Fundamentals of corrosion \|b mechanisms, causes, and preventative methods \|c Philip A. Schweitzer
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adam_text	Contents List of Figures ........................................................................................................xv List of Tables ........................................................................................................xix Preface .................................................................................................................xxiii 1 Introduction .....................................................................................................1 1.1 Economic Losses ...................................................................................1 1.2 Indirect Losses .......................................................................................2 1.2.1 Shutdown ..................................................................................2 1.2.2 Contamination ..........................................................................2 1.2.3 Loss of Product .........................................................................3 1.2.4 Loss of Efficiency .....................................................................3 1.2.5 Environmental Damage ..........................................................3 1.2.6 Overdesign ................................................................................3 1.3 Conservation Losses .............................................................................3 1.4 Nonmetallic Materials ..........................................................................4 1.5 Summary ................................................................................................4 2 Corrosion Mechanisms .................................................................................5 2.1 Cell Potentials ........................................................................................7 2.2 Types of Local Cell Formations ...........................................................8 2.2.1 Dissimilar Electrode Cells ......................................................9 2.2.2 Concentration Cells .................................................................9 2.2.3 Differential Temperature Cells ............................................10 2.2.4 Oxygen Concentration Cells ................................................11 2.2.5 Metal Ion Concentration Cells .............................................11 2.3 Potential-pH Diagrams ......................................................................11 2.4 Polarization ..........................................................................................14 2.4.1 Activation Polarization .........................................................15 2.4.2 Concentration Polarization ...................................................17 2.5 Measuring Polarization ......................................................................19 2.5.1 Anodic Polarization ...............................................................21 2.6 Other Factors Affecting Corrosion ...................................................23 2.7 Corrosion Rate Measurement ............................................................25 2.7.1 Corrosion Rate Expressions ..................................................25 3 Forms of Metallic Corrosion ......................................................................27 3.1 General (Uniform) Corrosion ............................................................27 3.1.1 Passive Film on Iron ..............................................................28 3.1.2 Passive Film on Nickel ..........................................................29 3.1.3 Passive Film on Austenitic Stainless Steel ..........................29 vi Contents 3.1.4 Passive Film on Copper .........................................................29 3.1.5 Passive Film on Aluminum .................................................. ЗО 3.1.6 Passive Film on Titanium .....................................................30 3.1.7 Passive Film on Tantalum .....................................................30 3.1.8 Uniform Corrosion Rates ......................................................30 3.1.9 Protective Measures ..............................................................31 3.2 Intergranular Corrosion .....................................................................32 3.2.1 Austenitic Stainless Steels ....................................................32 3.2.2 Ferritic Stainless Steels ..........................................................35 3.2.3 Other Alloys ...........................................................................35 3.3 Galvanic Corrosion .............................................................................36 3.3.3 Preventive Measures .............................................................38 3.4 Crevice Corrosion ...............................................................................38 3.4.1 Preventive Measures .............................................................40 3.5 Pitting Corrosion .................................................................................41 3.5.1 Preventive Measures .............................................................43 3.6 Erosion Corrosion ...............................................................................44 3.6.1 Preventive Measures .............................................................45 3.7 Stress Corrosion Cracking (SCC) ......................................................46 3.7.1 Preventive Measures .............................................................49 3.8 Biological Corrosion ............................................................................50 3.8.1 Preventive Measures .............................................................54 3.9 Selective Leaching ...............................................................................55 3.9.1 Preventive Measures .............................................................57 3.10 Hydrogen Damage ..............................................................................57 3.10.1 Sources of Hydrogen .............................................................58 3.10.2 Types of Hydrogen Damage .................................................59 3.10.2.1 Hydrogen Embrittlement ......................................59 3.10.2.2 Hydrogen Blistering ...............................................62 3.10.2.3 Flakes, Fisheyes, and Shatter Cracks ...................63 3.10.2.4 Hydrogen Attack ....................................................63 3.10.3 Preventive Measures .............................................................65 3.10.3.1 Hydrogen Blistering ...............................................65 3.10.3.2 Hydrogen Embrittlement ......................................66 3.10.3.3 Hydrogen Attack ....................................................67 3.11 Liquid Metal Attack ............................................................................68 3.11.1 Liquid Metal Embrittlement (LME) ....................................69 3.11.1.1 Requirements for Embrittlement .........................69 3.11.1.2 Factors Influencing LME .......................................71 3.11.1.3 Delayed Failure .......................................................72 3.11.1.4 Preventive Measures ..............................................72 3.11.2 Corrosion by Liquid Metals .................................................72 3.12 Exfoliation ............................................................................................73 3.12.1 Preventive Measures .............................................................74 3.13 Corrosion Fatigue ................................................................................74 Contents vii 3.13.1 Preventive Measures .............................................................75 3.14 Filiform Corrosion ..............................................................................75 3.14.1 Preventive Measures .............................................................76 References .......................................................................................................76 Atmospheric Corrosion ...............................................................................77 4.1 Atmospheric Types .............................................................................78 4.2 Factors Affecting Atmospheric Corrosion .......................................79 4.2.1 Time of Wetness .....................................................................80 4.2.1.1 Adsorption Layers ..................................................80 4.2.1.2 Phase Layers ............................................................81 4.2.2 Composition of Surface Electrolyte .....................................83 4.2.2.1 Oxygen .....................................................................83 4.2.2.2 SOX ............................................................................83 4.2.2.3 NOX ...........................................................................83 4.2.2.4 Chlorides .................................................................84 4.2.2.5 CO, ............................................................................84 4.2.2.6 Concentration of Different Species ......................84 4.2.3 Temperature ............................................................................84 4.2.4 Initial Exposure ......................................................................85 4.2.5 Sheltering ................................................................................85 4.2.6 Wind Velocity .........................................................................86 4.2.7 Nature of Corrosion Products ..............................................86 4.2.8 Pollutants Present ..................................................................87 4.3 Mechanisms of Atmospheric Corrosion of Metals ........................89 4.3.1 Damp Atmospheric Corrosion (Adsorption Layers) ........90 4.3.2 Wet Atmospheric Corrosion (Phase Layers) ......................92 4.3.2.1 Dew ..........................................................................92 4.3.2.2 Rain ..........................................................................92 4.3.2.3 Fog ............................................................................93 4.3.3 Deposit of Pollutants .............................................................93 4.4 Corrosion Products .............................................................................94 4.5 Specific Atmospheric Corrodents .....................................................96 4.5.1 Sulfur-Containing Compounds ...........................................97 4.5.2 Nitrogen-Containing Compounds ......................................99 4.5.3 Chlorine-Containing Compounds ....................................100 4.5.4 Carbon Dioxide (CO^ ..........................................................101 4.5.5 Oxygen (Ог) ...........................................................................101 4.5.6 Indoor Atmospheric Compounds .....................................101 4.6 Summary ............................................................................................101 4.7 Resistance of Specific Metals and Alloys to Atmospheric Corrosion ............................................................................................102 4.7.1 Carbon Steel ..........................................................................102 4.7.2 Weathering Steels .................................................................104 4.7.3 Zinc ........................................................................................106 viii Contents 4.7.4 Zinc and Zinc Alloy Coatings on Steel .............................109 4.7.4.1 Zinc-Aluminum Hot Dip Coatings .................... Ill 4.7.4.2 Zinc-Aluminum Thermally Sprayed Coatings ................................................................. Ill 4.7.4.3 Zinc-Iron Alloy Coatings ....................................112 4.7.4.4 Cast Zinc Alloys ...................................................112 4.7.5 Copper ...................................................................................112 4.7.6 Copper Alloys .......................................................................114 4.7.6.1 Brasses ....................................................................114 4.7.6.2 Bronzes ..................................................................116 4.7.6.3 Copper-Nickel Alloys ..........................................116 4.7.7 Aluminum Alloys ................................................................116 4.7.7.1 Protective Measures .............................................120 4.7.7.2 Applications ..........................................................121 4.7.8 Stainless Steel .......................................................................122 4.7.8.1 Austenitic Grades .................................................123 4.7.8.2 Ferritic Grades ......................................................124 4.7.8.3 Martensitic Grades ...............................................124 4.7.8.4 Duplex Grades ......................................................125 4.7.9 Nickel .....................................................................................125 4.7.10 Monel Alloy ..........................................................................125 4.7.11 Inconel Alloy 600.................................................................125 4.7.12 Inconel Alloy 625, Incoloy Alloy 800, Incoloy Alloy 825................................................................................126 4.8 Atmospheric Corrosion of Nonmetals ...........................................126 4.8.1 Plastics ...................................................................................126 4.8.1.1 Thermoplastics .....................................................127 4.8.1.2 Thermosets ............................................................129 4.8.2 Elastomers .............................................................................133 4.8.3 Masonry Materials ...............................................................134 4.8.3.1 Protecting Concrete .............................................137 4.8.3.2 Coating Selection ..................................................139 4.8.3.3 Polymer Concrete .................................................140 4.8.3.4 Mortars and Grouts ..............................................140 4.8.4 Ceramics ................................................................................141 4.8.4.1 Forms of Corrosion ..............................................143 4.8.4.2 Corrosion of Specific Ceramics ..........................145 4.8.5 Wood ......................................................................................145 4.8.5.1 Plywood .................................................................149 4.8.5.2 Reconstituted Wood Products ............................150 4.8.5.3 Applied Exterior Wood Finishes ........................151 4.8.6 Indoor Atmospheric Corrosion ..........................................153 References .....................................................................................................154 Contents ix 5 Corrosion of Polymer (Plastic) Materials ..............................................157 5.1 Radiation ............................................................................................158 5.2 Permeation .........................................................................................159 5.3 Absorption .........................................................................................163 5.4 Thermoplasts (Thermoplastic Polymers) .......................................166 5.5 Thermoset Polymers .........................................................................167 5.6 Environmental Cracking ..................................................................169 6 Corrosion of Linings ..................................................................................171 6.1 Liquid Applied Linings ....................................................................172 6.1.1 Design of the Vessel .............................................................172 6.1.2 Lining Selection ...................................................................176 6.1.3 Lining Application ...............................................................181 6.1.4 Cure of the Applied Lining ................................................182 6.1.5 Causes of Coating Failure ...................................................182 6.2 Sheet Linings .....................................................................................183 6.2.1 Shell Design ..........................................................................184 6.2.2 Considerations in Liner Selection ......................................185 6.2.2.1 Bonded Linings ....................................................186 6.2.2.2 Unbonded Linings ...............................................187 6.2.3 Design Considerations ........................................................188 6.2.3.1 Permeation .............................................................188 6.2.3.2 Absorption .............................................................190 6.2.4 Inspection of the Lining ......................................................191 6.2.5 Causes of Lining Failure .....................................................192 6.2.5.1 Liner Selection ......................................................192 6.2.5.2 Inadequate Surface Preparation .........................192 6.2.5.3 Thermal Stresses ..................................................192 6.2.5.4 Permeation .............................................................192 6.2.5.5 Absorption .............................................................193 6.2.5.6 Welding Flaws ......................................................193 6.2.5.7 Debonding .............................................................193 6.2.5.8 Operation ...............................................................193 6.2.5.9 Environmental Stress Cracking .........................193 6.3 Elastomeric Linings ..........................................................................194 7 Corrosion of Paint .......................................................................................197 . 7.1 Mechanisms of Protection ...............................................................198 7.2 Composition of Paint ........................................................................200 7.2.1 Binder .....................................................................................200 7.2.2 Pigments ................................................................................201 7.2.3 Solvents ..................................................................................202 7.2.4 Additives ...............................................................................204 7.2.5 Fillers (Extenders) ................................................................206 7.3 Causes of Bond and Coating Failures ............................................206 Contents 7.3.1 Surface Preparation and Application ................................207 7.3.2 Atmospheric Effects ............................................................207 7.3.3 Types of Failures ..................................................................210 7.3.3.1 Strength of Paint Film ..........................................210 7.3.3.2 Cohesive Failure ...................................................212 7.3.3.3 Stress and Chemical Failures .............................213 7.4 Types of Corrosion under Organic Coatings ................................213 7.4.1 Wet Adhesion .......................................................................214 7.4.2 Osmosis .................................................................................215 7.4.3 Blistering ...............................................................................215 7.4.4 Cathodic Delamination .......................................................216 7.4.5 Anodic Undermining ..........................................................217 7.4.6 Filiform Corrosion ...............................................................217 7.4.7 Early Rusting ........................................................................218 7.4.8 Flash Rusting ........................................................................218 7.5 Stages of Corrosion ...........................................................................218 7.5.1 First Stages of Corrosion .....................................................218 7.5.2 Second Stage of Corrosion ..................................................219 7.5.3 Third Stage of Corrosion .....................................................219 7.5.4 Fourth Stage of Corrosion ...................................................219 7.5.5 Fifth Stage of Corrosion ......................................................219 7.5.6 Final Stage of Corrosion ......................................................220 7.6 Surface Preparation ...........................................................................220 7.6.1 Metal Substrate Preparation ...............................................220 7.6.1.1 Abrasive Cleaning ................................................222 7.6.1.2 Detergent Cleaning ..............................................222 7.6.1.3 Alkaline Cleaning ................................................223 7.6.1.4 Emulsion Cleaning ...............................................223 7.6.1.5 Solvent Cleaning ...................................................223 7.6.1.6 Vapor Degreasing .................................................223 7.6.1.7 Steam Cleaning .....................................................223 7.6.2 Metal Surface Pretreatment ................................................223 7.6.2.1 Aluminum .............................................................224 7.6.2.2 Copper ....................................................................224 7.6.2.3 Galvanized Steel ...................................................224 7.6.2.4 Steel ........................................................................224 7.6.2.5 Stainless Steel ........................................................224 7.6.2.6 Titanium ................................................................224 7.6.2.7 Zinc and Cadmium ..............................................225 7.6.3 Plastic Substrate Preparation ..............................................225 7.6.3.1 Solvent Cleaning ...................................................226 7.6.3.2 Detergent Cleaning ..............................................226 7.6.3.3 Mechanical Treatments .......................................227 7.6.3.4 Chemical Treatment .............................................227 7.6.3.5 Other Treatments ..................................................229 Contents xi 7.7 Application of Coatings ....................................................................229 7.7.1 Application Methods ...........................................................230 7.7.1.1 Brushing ................................................................231 7.7.1.2 Rolling ....................................................................231 7.7.1.3 Roller Coating .......................................................231 7.7.1.4 Spray Painting .......................................................232 7.7.1.5 Powder Coating ....................................................233 7.7.1.6 Electrodeposition of Polymers ............................234 7.7.2 Multilayer Coatings .............................................................235 7.7.3 Curing ....................................................................................238 7.7.3.1 Air-Drying .............................................................239 7.7.3.2 Baking ....................................................................239 7.7.3.3 Force Drying .........................................................240 7.7.3.4 Reflowing ...............................................................240 7.7.3.5 Radiation Curing ..................................................240 7.7.3.6 Vapor Curing .........................................................240 7.7.4 Inspection ..............................................................................240 7.8 Maintenance of the Coating ............................................................241 7.9 Selecting a Paint System ...................................................................242 7.9.1 Area 1: Mild Exposure ........................................................247 7.9.2 Area 2: Temporary Protection, Normally Dry Interiors .................................................................................248 7.9.3 Area 3: Normally Dry Exteriors .........................................248 7.9.4 Area 4: Freshwater Exposure .............................................250 7.9.5 Area 5: Saltwater Exposure ................................................251 7.9.6 Area 6: Freshwater Immersion ...........................................251 7.9.7 Area 7: Saltwater Immersion ..............................................251 7.9.8 Area 8: Acidic Chemical Exposure (pH 2.0-5.0)..............251 7.9.9 Area 9: Neutral Chemical Exposure (pH 5.0-10.0)..........252 7.9.10 Area 10: Exposure to Mild Solvents ..................................252 7.9.11 Area 11: Extreme pH Exposure ..........................................252 8 Corrosion of Metallic Coatings ...............................................................255 8.1 Corrosion Cell ....................................................................................255 8.2 EMF Control Protection by Noble Metals .....................................264 8.2.1 Mechanism of Control Protection .....................................264 8.2.1.1 Copper Coatings ...................................................264 8.2.1.2 Gold Coatings .......................................................266 8.3 Anodic Control Protection by Noble Metals .................................267 8.3.1 Mechanisms of Control Protection ....................................267 8.3.1.1 Nickel Coatings ....................................................267 8.3.1.2 Chromium Coatings ............................................271 8.3.1.3 Tin Coatings (Tinplate) ........................................273 8.3.1.4 Lead Coatings .......................................................276 8.4 Cathodic Control by Sacrificial Metal Coatings ...........................277 xii Contents 8.4.1 Mechanism of Control Protection .....................................281 8.4.1.1 Zinc Coatings ........................................................281 8.4.1.2 Corrosion of Zinc Coatings .................................283 8.4.1.3 Zinc^/o Aluminum Hot Dip Coatings .............285 8.4.1.4 Zinc-55% Aluminum Hot Dip Coatings ...........286 8.4.1.5 Zinc-^/o Aluminum Thermal Spray ................287 8.4.1.6 Zinc-Iron Alloy Coatings ....................................288 8.4.1.7 Aluminum Coatings ............................................289 8.4.1.8 Cadmium Coatings ..............................................289 8.4.1.9 Manganese Coatings ............................................290 8.5 Mixed Control Protection ................................................................290 8.5.1 Phosphate Coatings .............................................................291 8.5.2 Chromáte Coatings ..............................................................292 8.5.3 Oxide Coatings .....................................................................294 8.5.4 Anodized Coatings ..............................................................295 8.6 Eclipse Molding Framework (EMF) Control Protection ..............296 9 Cathodic Protection ....................................................................................297 9.1 Background ........................................................................................297 9.2 Theory .................................................................................................298 9.2.1 Sacrificial Anodes ................................................................300 9.2.1.1 Anode Requirements ...........................................300 9.2.1.2 Anode Materials and Backfill .............................303 9.2.2 Impressed Current Systems ...............................................303 9.2.2.1 Current Requirements .........................................304 9.2.2.2 Anode Materials and Backfill .............................304 9.2.2.3 Testing for Completeness of Protection ............305 9.3 Use with Coatings .............................................................................306 9.4 Economics ..........................................................................................307 10 Corrosion Inhibitors ..................................................................................309 10.1 Inhibitor Evaluation ..........................................................................310 10.2 Classification of Inhibitors ...............................................................311 10.2.1 Passivation Inhibitors ..........................................................311 10.2.1.1 Mechanism of Passivation ..................................311 10.2.2 Organic Inhibitors ................................................................315 10.2.3 Precipitation Inhibitors (Cathodic Inhibitors) ..................317 10.2.4 Vapor-Phase Inhibitors ........................................................317 10.3 Inhibition in Acid Solution ..............................................................318 10.3.1 Physical Adsorption ............................................................319 10.3.2 Chemisorption .....................................................................320 10.3.3 Interactions between Adsorbed Inhibitors ......................321 10.3.4 Relationships between Inhibitor Reactivity and Efficiency ...............................................................................321 10.4 Inhibition of Near-Neutral Solutions .............................................321 Contents xiii 10.5 Inhibition of Alkaline Solutions.....................................................323 10.6 Temporary Protection with Inhibitors ...........................................323 10.7 Inhibition of Localized Corrosion ..................................................324 10.8 Summary ............................................................................................326 References .....................................................................................................326 11 The Equipment Design Process ...............................................................329 11.1 Understanding the Application ......................................................329 11.2 Selecting Materials of Construction ...............................................332 11.3 Controlling Corrosion by Design ...................................................335 11.3.1 Protection from Atmospheric Corrosion ..........................335 11.3.1.1 General Design Considerations ..........................336 11.3.1.2 Structures ..............................................................337 11.3.1.3 Electrical Components .........................................339 11.3.1.4 Control Rooms ......................................................339 11.3.1.5 Protection of Carbon Steel ..................................340 11.3.2 Corrosion under Insulation ................................................342 11.3.2.1 Selecting a Suitable Insulation Material ...........342 11.3.2.2 Design Characteristics of Insulation .................344 11.3.2.3 Comparison of Jacketing .....................................348 11.3.2.4 Design Requirements for Various Services and Systems ...........................................................350 11.3.3 Industries and Systems Covered .......................................355 11.3.3.1 Chemical Industry ...............................................356 11.3.3.2 Petroleum Refining Industry ..............................358 11.3.3.3 Water Treatment and Supply Systems ...............363 11.3.3.4 Design Features ....................................................370 11.3.5 Gas Industry .........................................................................371 11.3.5.1 Types of Corrosion in Underground Piping .... 371 11.3.5.2 Methods of Control ..............................................372 11.3.6 Pipeline Industry .................................................................372 11.3.6.1 Coatings .................................................................372 11.3.6.2 Cathodic Protection .............................................373 11.3.6.3 Internal Corrosion ................................................374 11.3.7 Marine Industry ...................................................................374 11.3.7.1 Protection of Condensers and Saltwater Exchangers ............................................................375 11.3.7.2 Use of Aluminum in Marine Service ................375 Index .....................................................................................................................379
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author	Schweitzer, Philip A.
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discipline	Physik Werkstoffwissenschaften / Fertigungstechnik
format	Book
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id	DE-604.BV035987387
illustrated	Illustrated
indexdate	2024-07-09T22:09:04Z
institution	BVB
isbn	9781420067705
language	English
lccn	2009028737
oai_aleph_id	oai:aleph.bib-bvb.de:BVB01-018880179
oclc_num	156818649
open_access_boolean
owner	DE-703 DE-83
owner_facet	DE-703 DE-83
physical	XXIII, 403 S. graph. Darst.
publishDate	2010
publishDateSearch	2010
publishDateSort	2010
publisher	CRC Press, Taylor & Francis
record_format	marc
spelling	Schweitzer, Philip A. Verfasser aut Fundamentals of corrosion mechanisms, causes, and preventative methods Philip A. Schweitzer Boca Raton, Fla. [u.a.] CRC Press, Taylor & Francis 2010 XXIII, 403 S. graph. Darst. txt rdacontent n rdamedia nc rdacarrier Building materials Corrosion Corrosion and anti-corrosives Korrosion (DE-588)4032518-0 gnd rswk-swf Korrosion (DE-588)4032518-0 s DE-604 Digitalisierung UB Bayreuth application/pdf http://bvbr.bib-bvb.de:8991/F?func=service&doc_library=BVB01&local_base=BVB01&doc_number=018880179&sequence=000002&line_number=0001&func_code=DB_RECORDS&service_type=MEDIA Inhaltsverzeichnis
spellingShingle	Schweitzer, Philip A. Fundamentals of corrosion mechanisms, causes, and preventative methods Building materials Corrosion Corrosion and anti-corrosives Korrosion (DE-588)4032518-0 gnd
subject_GND	(DE-588)4032518-0
title	Fundamentals of corrosion mechanisms, causes, and preventative methods
title_auth	Fundamentals of corrosion mechanisms, causes, and preventative methods
title_exact_search	Fundamentals of corrosion mechanisms, causes, and preventative methods
title_full	Fundamentals of corrosion mechanisms, causes, and preventative methods Philip A. Schweitzer
title_fullStr	Fundamentals of corrosion mechanisms, causes, and preventative methods Philip A. Schweitzer
title_full_unstemmed	Fundamentals of corrosion mechanisms, causes, and preventative methods Philip A. Schweitzer
title_short	Fundamentals of corrosion
title_sort	fundamentals of corrosion mechanisms causes and preventative methods
title_sub	mechanisms, causes, and preventative methods
topic	Building materials Corrosion Corrosion and anti-corrosives Korrosion (DE-588)4032518-0 gnd
topic_facet	Building materials Corrosion Corrosion and anti-corrosives Korrosion
url	http://bvbr.bib-bvb.de:8991/F?func=service&doc_library=BVB01&local_base=BVB01&doc_number=018880179&sequence=000002&line_number=0001&func_code=DB_RECORDS&service_type=MEDIA
work_keys_str_mv	AT schweitzerphilipa fundamentalsofcorrosionmechanismscausesandpreventativemethods

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